WO2007010526A2

WO2007010526A2 - Modular knockdown furniture

Info

Publication number: WO2007010526A2
Application number: PCT/IL2006/000817
Authority: WO
Inventors: Doron Lachish
Original assignee: Doron Lachish
Priority date: 2005-07-21
Filing date: 2006-07-13
Publication date: 2007-01-25
Also published as: WO2007010526A3

Abstract

The present invention discloses a knockdown put-together article of furniture, comprising at least two modules, and at least one module-connecting component; said at least one of said at least two modules comprises two horizontal panels and two vertical panels; said horizontal panels are identical to each other and said vertical panels are identical to each other; at least one of said horizontal panels is connected to at least one of said vertical panels, and said module-connecting component is either connected to at least two of said horizontal panels, or connected to at least two of said vertical panels. The present invention also discloses a method of manufacturing a knockdown put-together modular article of furniture, constructed of horizontal and vertical panel components.

Description

MODULAR KNOCKDOWN FURNITURE

FIELD OF THE INVENTION

The present invention generally relates to modular knockdown furniture. More specifically, the present invention relates to a knockdown, put-together article of furniture, such as a cupboard, storage cabinet, bookcase, and the like, comprising modules, which mass-produced parts can be packaged and shipped in a knocked- down disassembled condition and readily assembled by the use of common tools.

BACKGROUND OF THE INVENTION

This invention relates generally to knockdown furniture, and more particularly to a module capable of being grouped into multiples to define various articles of furniture, the module being formed of four panels which may be joined together to create an open-ended box.

US Pat No. 4,169,639 discloses a knockdown furniture module, and well explains the economic rational for furniture to be built in such a way.

Furniture such as cupboard, storage cabinets and book-cases are used for the storage of various objects. Their function dictates a large ratio of volume of interior space to furniture weight. Their function also suggests horizontal panels on which stored objects can be placed without gravity pulling them to one side or the other. The shape of a box fits these two requirements well, and is thus basic to many articles of furniture. The box is bounded by two horizontal and two verticals walls or panels. A structure composed of box module is bulky, as dictated by its function, when it is fulfilling its function, but a bulky structure is expensive to store and transport. At the time of storage or transport, it is convenient to deal with stackable components, preferably flat and preferably identical, or with standard small components that can be stored and transported in bulk, such as screws, nails, nuts and bolts

The existence of knock-down furniture in two states as described above, implies a stage in which a piece of furniture is constructed and erected, which takes place preferably by the user and preferably on location. Knock-down furniture need to be assembled by a layman using tools that are commonly available such as screwdrivers. Knock-down furniture is preferably designed and built for the masses. The larger the number of units built and sold the cheaper each unit can be made. Different users of the same furniture may require it in different sizes, and the same piece of furniture may need to change its size as usage requirements change over time. Therefore, it is preferable for knock-down furniture to be modular, i.e. to comprise of modules. Modules can be added or removed from an assembled modular piece of furniture as requirements change over time, and different users can purchase a different number of modules according to their varying requirements and means.

Plastic materials are suitable for making components for knock-down furniture, because they allow the design of components that are strong and stackable. Components can be made by injecting plastic material into moulds, and the shape of the components is dictated by the shape of the mould. This process of manufacture implied that it is preferable for plastic furniture to be composed of the minimum of different components, so that the number of identical units manufactured is maximized. Optimally, the number of different plastic components composing a module of knockdown furniture is one. However, the manufacturing process of injecting plastic material into moulds poses some demands on the material selected and the shape of the mould. Plastic materials of high viscosity require moulds of short length of flow, which forces the point of injection to be close to the center of the component created by injection. Some furniture is intended to be placed in highly visible locations, such as living rooms, and is thus required to possess aesthetic appearance. Demands are made of the physical properties of such furniture, which may conflict with considerations of price and rigidity. Often, a mark is formed at the point of injection of plastic material into the mould, which is not aesthetically pleasing, unless it is covered by other components of the furniture.

There are a great number of designs for modular knockdown furniture known in the art. Many designs are listed in US Pat No 4470647, for example.

However, there still exists a need for a quality design that presents the optimum solution for aesthetically pleasing furniture, and being modular, with each module containing the minimum of components, and minimizing the costs of transport, storage and construction to achieve the highest level of quality at a competitive price. SUMMARY OF THE INVENTION

It is an object of the present invention to provide a knockdown put-together article of furniture, comprising at least two modules, and at least one module-connecting component. Said at least one of said at least two modules comprises two horizontal panels and two vertical panels. Said horizontal panels are identical to each other, and said vertical panels are identical to each other. At least one of said horizontal panels is connected to at least one of said vertical panels, and said module-connecting component is either connected to at least two of said horizontal panels, or connected to at least two of said vertical panels.

It is further in the scope of the present invention that at least one of said horizontal panels forms the shape of a horizontal trapeze in cross-section.

It is further in the scope of the present invention that at least one of said vertical panels forms the shape of a vertical trapeze in cross-section.

It is further in the scope of the present invention that said module-connecting component is hexagonal in cross-section.

It is further in the scope of the present invention that at least one of the two edges of said horizontal trapeze that are not horizontal is serrated.

It is further in the scope of the present invention that at least one of the two edges of said vertical trapeze that are not vertical is serrated.

It is further in the scope of the present invention that the horizontal panels are identical to said vertical panels.

It is another object of the present invention to provide a knockdown put-together article of furniture comprising at least a first and a second modules and at least one module-connecting component. Said first module comprises at least three panel components, comprising inter alia a first panel, and a second panel. Said second module comprises at least three panel components, comprising inter alia a third panel.

Said first panel is connected to said second panel, and said module-connecting component is connected to both said first panel and to said third panel.

It is further in the scope of the present invention that all but one face of each of said panels are completely covered by other components when the article is in its put together state.

It is yet another object of the present invention to provide a knockdown put-together article of furniture comprising identical panel components, and at least a first and a second module. Said first module comprises at least three panel components, comprising inter alia a first panel, and a second panel. Said second module comprises at least three panel components, comprising inter alia a third panel. Each of said panels comprising two parallel faces and two slanted faces; said first panel is connected to said second panel via their slanted faces, and said first panel is connected to said third panel via their parallel faces.

It is further in the scope of the present invention that each of said slanted faces is serrated.

It is another object of the present invention to provide a method of manufacturing a knockdown put-together modular article of furniture, constructed of either identical or non-identical panel components, comprising the following steps: a. forming a mold for a panel having a back face, a front face and two serrated slanted faces; b. injecting plastic material into the mold at said back face of said panel; c. transporting said panel to a construction site; d. connecting two of said panels back to back.

It is yet another object of the present invention to provide a method of manufacturing a knockdown put-together modular article of furniture, constructed of either identical or non-identical panel components, comprising the following steps a. forming a mold for a panel; b. injecting plastic material into the mold at injection points; c. transporting said panel to a construction site; d. connecting panels together; wherein each and every injection point of each and every connected panel is covered by another connected panel.

BRIEF DESCRIPTION OF THE FIGURES

In order to understand the invention and to see how it may be implemented in practice, a preferred embodiment will now be described, by way of non-limiting example only, with reference to the accompanying drawing, in which figure 1 schematically presents a piece of furniture comprising four modules, figure 2a schematically presents a piece of furniture composed of one type of component only, figure 2b schematically presents one box-shaped module comprising four components, figure 3 schematically presents a detail of figure 1 showing one box-shaped module, figure 4 schematically presents a module-connecting component, figures 5a and 5b schematically present details of a panel component for back-to-back attachment, figures 6a and 6b schematically present panel components attached side-by-side, figure 7 schematically presents a type of serrated edge having two regions.

DETAILED DESCRIPTION OF THE PREFFERED EMBODIMENTS

The following description is provided, alongside all chapters of the present invention, so as to enable any person skilled in the art to make use of said invention and sets forth the best modes contemplated by the inventor of carrying out this invention. Various modifications, however, will remain apparent to those skilled in the art, since the generic principles of the present invention have been defined specifically to provide modular knock-down furniture.

The term 'modular furniture' refers in the present invention to any piece of furniture that is constructed of a variable number of similar modules.

The term 'knockdown furniture' refers in the present invention to any piece of furniture that assembled on location of a small number of components, used, and then disassembled to its components.

The tern, 'component' refers in the present invention to any part of a larger structure which significantly contributes to the size, weight and cost of the structure. For example, many tables comprise of five components: one flat board, and four legs.

The term 'connecting element' refers in the present invention to any part of a larger structure which contribution to the size, weight and cost of the structure is insignificant, and which function is to connect some components of the structure Io each other. Screws, nuts, bolts, nails and pins are examples of connecting elements. The term "plastic' refers in the present invention to a material suitable for making furniture components ^"by injecting or pouring it into moulds, for example ABS, polypropylene and poly-carbonate.

The modular knock-down furniture according to a most general embodiment of the present invention is schematically characterized by two types of components a module-connecting component, and a panel component. A module-connecting component attaches one box-shaped module to another while providing aesthetic appearance the furniture. Each box-shaped module is constructed of a plurality of panel components, typically four.

Reference is thus made now to figure 1 , presenting a preferred embodiment of the aforementioned novel modular knock-down furniture. A piece of furniture 100 is composed of a plurality of box-shaped modules. Four modules are depicted in figure 1 , but it is possible to add any number of modules to the depicted arrangement, or to remove modules. The piece of furniture 100 comprises components of two types: module-connecting component, and a panel component. Some components are placed horizontally, and some vertically. For example, component 10 is a horizontal panel component, component 20 is vertical panel component, component 30 is a vertical module-connecting component, and component 40 is a horizontal module-connecting component. Other components of the same types are also depicted in figure I , but no other types of components are required for the construction of the piece of furniture except connecting elements as described herein below. All components are preferably made of plastic, though they could also be made of other materials, for example metal and wood. According to a preferred embodiment of the present invention, all horizontal components are identical to all vertical components, so that piece of furniture 100 comprises of two types of components. According to the preferred embodiment of the present invention, the components are made of plastic, so that only two moulds need to be prepared for the manufacture of knockdown furniture o£ any number of modules. Furthermore, a small package containing the minimum number of components, for example, two of each type, can be defined and sold to users, so a user can save costs by buying a discrete number of packages having exactly the number of components required to erect any desired piece of furniture.

Figure 1 depicts a preferred embodiment of the present invention, built to a rectangular grid, with four panels forming each module. This embodiment is relatively strong, having the force of gravity acting vertically in alignment with the vertical panels. It is explained in reference to figures 6a and 6b herein below, that gravity is prevented from acting horizontally by some features of the edges of the panel components, even when some edges of these components are slanted. Other embodiments of the present invention may be built to other regular grids, for example a hexagonal grid with six panels forming each module, like a honeycomb. Other embodiment of the present invention may be built to non-regular grids, for example according to Penrose tiles.

Reference is now made to figure 2a, showing a piece of furniture constructed of one type panel component 260, according to an embodiment of the present invention, with every four components forming a module. Modules are connected together using connecting elements such as screws 51 and 52. Economy of scale allows the manufacture, storage, transport, and sale of such a piece of furniture to be the most efficient, as no piece of furniture is possible with a lesser number of types of components than one.

Reference is now made to figure 2b, presenting one of the modules of which the piece of furniture depicted in figure 1 or figure 2a is composed. This box-shaped module comprises four components of the panel type, two horizontal panels, and two vertical panels. For example, component 250 is a horizontal panel, and component 260 is a vertical panel. Figure 2b also shows that there may exist some connecting elements used to connect the panel components to each other. For example screw 50, in conjunction with nut 60 is shown to connect panel 250 to panel 260. Many types of connecting elements are known in the art to be suitable for this purpose, including screws of many types and sizes. In the preferred embodiment of the present invention, the panel components are designed to accommodate the connecting elements. For example, holes pass through the panels to allow the insertion of screw 50. Figure 2b shows four such holes passing through each panel, and hole 220 is one of them. The function of elements 210 and 211 is described in reference to figure 4, figure 5 A and 5B. First, and as explained herein below in reference to figure 4, they comprises a hole allowing for the insertion of connecting elements such as a pin. Second, and according to the preferred embodiment of the present invention, they are designed to fit together when identical panels are places back-to-back, causing some attachment between panels, as explained herein below in reference to figure 5a and 5b. According to the preferred embodiment of the present invention, panel 250, like all panels, forms the shape of trapeze in cross section. Of the two parallel edges of the trapeze, the shorter belongs to a face of panel 250 that forms the inner volume of the module. The longer of the parallel edges defines a face for the panel that is to be covered by a matching face of another identical panel. Because it is to be covered, it may comprise points in which plastic is injected into the mould forming the panel, without forming an aesthetically displeasing mark, even when these points are close to the center of the face. The two other edges are where a vertical panel meets a horizontal panel, at faces of the panels that are shown in figure 2b to be serrated. According to the preferred embodiment of the present invention, these faces are not smooth faces. These surfaces are rough, grooved, serrate, containing bumps, stairs, teeth, or any form of texture preventing them from sliding one against the other as the structure is put under stress, because it prevents the force of gravity from being directed sideways. This is explained in further detail in reference to figures 6a and 6b.

Reference is now made to figure 3, which is a detail cut from figure 1, presenting one of the module of which the piece of furniture is composed. Vertical panel 21, together with horizontal panel 11, and two other panels compose a first box-shaped module, similar to the module depicted in figure 2b. Vertical panel 22 is attached to panel 21 back to back, and horizontal panel 12 is attached to panel 11 back to back. In fact, all four panels composing the first module have matching panels attached back to back. Vertical panel 23 and horizontal panel 13 are thus attached to panels of the first module, while consisting parts of other modules of the same piece of furniture. Figure 3 shows that the means of attaching panel components back to back according to the present invention is the module-connecting component. Component 30, for example, connects components 21 and 22 together, and component 40 connects components 1 1 and 12 together. Component 31 connects the first module with the module composed of panel 23, and component 32 connects the first module with the module composed of panel 13, in this example. In the preferred embodiment of the present invention, a module-connecting component attaches two panels together by engulfing them. The shape of module-connecting components fits two panel components attached back to back. Figure 2b shows that when the piece of furniture is fully assembled, the back sides of the panel components are covered, because they attached hack to back to each other. Figure 2b also shows that the sides of the panel components are also covered (when the piece of furniture is fully assembled) by the module-connecting components. In fact, the only faces of any component not covered are the outer faces of the module-connecting components and one face of each of the panels. Furthermore, the front side of the piece of furniture is composed only of outer faces of the module-connecting components. Therefore, these are the only faces that need to be aesthetically pleasing. In a preferred embodiment of the present invention, the module-connecting components are also present at the back of the piece of furniture, for example component 25. This adds mechanical strength to the structure. There are holes depicted in the module-connecting components in figure 3, for example, hole 410 in component 40. These holes are explained herein below in reference to figure 4.

Reference is now made to figure 4, which depicts a module-connecting component according to the preferred embodiment of the present invention. This is, for example, component 40 also shown in figures 1 and 3. Its shape fits two panels back to back, in this case hexagonal, and its outer faces are preferably aesthetically pleasing, i.e. having pleasing color and texture. The shape of component 40 preferably accommodates some connecting elements. In a preferred embodiment of the present invention, component 40 comprises holes, such as hole 410, also shown in figure 3, and fitting corresponding holes in other components, such as hole 210 mentioned in reference to figure 2b, and into which connecting elements, such as pins, may be inserted. Any pin that fits both holes is suitable, and the pin may be made of any solid material, for example plastic, wood or metal. In a preferred embodiment of the present invention, component 40 comprises grooves, such as groove 420, fitting the detail of the shape of the panel components that allows them to be connected together, for example fitting item 220 described in reference to figure 2b.

Reference is now made to figure 5a and 5b, which schematically show details of panel components according to the preferred embodiment of the present invention, which function is to facilitate panels to be attached back to back. They are marked by numerals 210 and 21 1 in these figures as in figure 2b. When two panel components are placed back to back, elements 210 and 211 become in contact with each other. Their complementary shape causes them to attach to each other and so to assist the attachment of their panels. A hole passes through both elements allows the insertion of a pin to further strengthen the attachment of the panels back to back to each other. Reference is now made to figure 6a and 6b, which schematically show two panel components attached side by side. Panel 600 is marked in bold lines, and it is identical to panel 610. Both panels are roughly trapezes, but each comprises two side edges that are serrated, for example edges 620 and 630. Edge 620 complements edge 630, so that they caii be fitted together. Figure 6a shows that while the edges are slanted in an angle of 45 degrees, gravity pulling panel 610 (and any weight on it) down, does not cause it to slip to the left, because of the existence of the serration. The function of screw 50 shown in figure 6b is explained in reference to figure 2b. Figures 6a and 6b further describes the form and function of the panel component, as described in reference to figure 2b, with figure 6a being more schematic and general, and figure 6b describing the preferred embodiment of the present invention in detail so that modular knockdown furniture can be built by those skilled in the art.

Reference is now made to figure 7 schematically presenting a detail view from a constructed piece of furniture such as shown in figure 1. Figure 7 shows a type of serrated edge according to a preferred embodiment of the present invention as also shown in figure 6b. Serrated region 710 belongs to one panel, and serrated region 720 belongs to another panel. This design achieves the physical robustness described in reference to figure 6a with pleasing appearance, even in case when a module connecting component is not used, as region 710 and region 720 appear to form one continuous region of uniform texture, even though they are not identical, as explained in reference to figure 6a and 6b.

Furniture according to the present invention can be assembled and disassembled by a laymen, without resorting to expensive labor or to special tools.

Furniture according to the present invention allow for significant saving in the cost of transport, storage and construction, which allows for investment in the manufacture of plastic component of high quality, resulting in products that are competitive in price and superior in quality. For example, transparent, translucent (made of Polycarbonate PC, Acrylic PMMA, etc.). hard (resistant to scratches) plastic materials may be selected, sometimes having high viscosity. No mark is seen at the point of injection of plastic material into the mould according to the present invention, a fact that allows aesthetically pleasing furniture.

Furniture according to the present invention may be sold through a variety of channels, including cash & carry outlets, as well as mail order and internet virtual shops. This is due to modularity, and to the low volume and light weight of its component before assembly. The present invention makes use of plastic components that are so molded that they are lighter in weight than wood, glass and metal components of the same volume.

Claims

Claims:

[1] A knockdown put-together article of furniture, comprising at least two modules, and at least one module-connecting component; said at least one of said at least two modules comprises two horizontal panels and two vertical panels; said horizontal panels are identical to each other and said vertical panels are identical to each other; at least one of said horizontal panels is connected to at least one of said vertical panels, and said module-connecting component is either connected to at least two of said horizontal panels, or connected to at least two of said vertical panels.

[2] The furniture according to claim 1 wherein at least one of said horizontal panels forms the shape of a horizontal trapeze in cross-section.

[3] The furniture according to claim 2 wherein at least one of said vertical panels forms the shape of a vertical trapeze in cross-section.

[4] The furniture according to claim 3 wherein said module-connecting component is hexagonal in cross-section.

[5] The furniture according to claim 2 wherein at least one of the two edges of said horizontal trapeze that are not horizontal is serrated.

[6] The furniture according to claim 3 wherein at least one of the two edges of said vertical trapeze that are not vertical is serrated.

[7] The furniture according to any of the previous claims, wherein the horizontal panels are identical to said vertical panels.

[8] A knockdown put-together article of furniture comprising at least a first and a second modules and at least one module-connecting component; said first modules comprises at least tliree panel components, comprising inter alia a first panel, and a second panel; said second modules comprises at least three panel components, comprising inter alia a third panel; said first panel is connected to said second panel; and said module-connecting component is connected to both said first panel and to said third panel.

[9] The furniture according to claim 8, wherein all but one face of each of said panels are completely covered by other components when the article is in its put together state.

[10] A knockdown put-together article of furniture comprising identical panel components, and at least a first and a second module; said first module comprises at least three panel components, comprising inter alia a first panel, and a second panel; said second modules comprises at least three panel components, comprising inter alia a third panel; each of said panels comprising two parallel faces and two slanted faces; said first panel is connected to said second panel via their slanted faces; said first panel is connected to said third panel via their parallel faces.

[11] A knockdown put-together article of furniture according to claim 10, wherein each of said slanted faces is serrated.

[12] A knockdown, put-together article of furniture substantially as depicted in any of the figures.

[13] A method of manufacturing a knockdown put-together modular article of furniture, constructed of horizontal and vertical panel components, comprising the following steps; a. forming a mold for a panel having a back face, a front face and two serrated slanted faces; b. injecting plastic material into the mold at said back face of said panel; c. transporting said panel to a construction site; d. connecting two of said horizontal panels back to back; e. connecting two of said vertical panels back to back,

[14] A method of manufacturing a knockdown put-together modular article of furniture according to claim 13, wherein said horizontal panel components are identical, and said vertical components are identical.

[15] A method of manufacturing a knockdown put-together modular article of furniture, constructed of horizontal and vertical panel components, comprising the following steps; a. forming a mold for a panel; b. injecting plastic material into the mold at injection points; c. transporting said panel to a construction site; d. connecting panels together; wherein each and every injection point of each and every connected panel is covered by another connected panel.

[16] A method of manufacturing a knockdown put-together modular article of furniture according to claim 15, wherein said horizontal panel components are identical, and said vertical panel components are identical.